Systems and Methods for Modular Building Construction with Integrated Utility Service

ABSTRACT

Systems and methods for construction using modular units, such as wall panels, which have integrated utility service. One embodiment comprises a product including a modular construction panel and one or more utility fittings which are integral to the panel. The utility fittings may be for any type of utility service, such as electrical, plumbing, HVAC, computer network, phone or audio/video service. The fittings in the panels may be electrical wires or plumbing conduits. The panels may include connectors (e.g., quick-connect connectors) for coupling the utility fittings which are integral to the panel to service points such as wiring harnesses or water source pipes that are external to the panel and that provide utility service to the utility fittings. The panels may also include connectors for coupling the integral utility fittings to utility fixtures external the panel, such as light switches, electrical outlets, computer network jacks, phone jacks, faucets, drains, etc.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication 60/864,069, filed Nov. 2, 2006, which is incorporated byreference as if set forth herein in its entirety.

BACKGROUND

1. Field of the Invention

The invention relates generally to systems and methods for construction,and more particularly to systems and methods for constructing buildingsusing modular units, such as wall panels, which have integrated utilityservice.

2. Related Art

The invention relates generally to systems and methods for construction,and more particularly to systems and methods for constructing buildingsusing modular units, such as wall panels, which have integrated utilityservice.

Methods for building construction, and especially methods forconstructing residential buildings have stayed, for the most part,unchanged for many years. This is an industry which is very conventionalend which is very slow to change. It is also very difficult to convincepeople in the industry to accept changes. Traditional constructionmethods are well known and understood by these people, and they aretypically are reluctant to adopt construction methods that representdramatic changes in the way buildings are constructed.

Traditional residential construction begins with construction of afoundation that incorporates basic plumbing connections (e.g.,freshwater, wastewater, gas.) Wood construction is then utilized in theframing of the building. After the wood frame is constructed, exteriorwalls and roof are attached to the frame. Then, plumbing, electricalwiring and air conditioning/heating systems are installed. Most of theplumbing and electrical wiring are installed within the framed walls andceiling of the building. A/C ducting may also be installed in the wallsand ceiling. Interconnections of the wiring, plumbing and ducting may bemade in available attic space or elsewhere in the building. After thesetrades are completed, the interior walls may be closed (i.e., drywallinstalled) and the interior is finished out (e.g., electrical fixturesand plumbing fixtures installed.)

These traditional construction methods have various drawbacks. Forexample, progress in constructing the building is typically very slow.There are several reasons for this. First, the construction must proceedin stages, and some of these stages cannot be begun until others havebeen completed. For example, it is necessary to complete the framing ofthe house before plumbing (at least to the portion of the plumbing abovethe foundation) can be installed. Similarly, electrical wiring andducting cannot be installed until the framing is completed. Because eachof these utilities (water/wastewater, electricity, air conditioning) isinstalled by different tradespeople (e.g., plumbers, electricians) inthe same wall space, it may be difficult to install them at the sametime. Consequently, it may be necessary to complete installation of onebefore beginning installation of another, thus adding to the timerequired for the construction. Still further, although thesetradespeople normally have a construction plan to follow in performingtheir respective trades, it is typically the case that there areproblems in the installation (e.g., plumbing installed at the wronglocation) which require the tradespeople to return after their jobs werebelieved to have been completed, in order to correct the problems. This,of course, adds to the construction time.

Another drawback of traditional wood-frame construction is that lumberis an increasingly scarce resource. It is difficult to renew forests atthe rate at which they are harvested to provide lumber for construction.In addition to the obvious environmental concerns this presents, thedecreasing supply of wood also leads to increased cost, as the woodbecomes more expensive.

As noted above, the construction industry, and particularly peopleinvolved in residential construction, have been very slow to acceptchanges or alternatives to conventional construction methods. Thecommercial side of the industry, however, has made some use ofalternative construction methods, and at least some of these alternativemethods are available for residential construction. For example, it isnow quite common in commercial buildings to make use of steel framing.Internal walls of commercial buildings often use steel C-channel studsinstead of 2×4 wood studs. The use of steel studs for internal framingprovides one solution to the problem of dwindling lumber resources, buta lack of familiarity with steel construction has slowed adoption ofthis construction method in residential applications.

Another advance in construction is the use of prefabricated walls orpanels to construct the frame of a building. In large commercialbuildings, these prefabricated walls may consist of concrete slabs orpanels having preformed door or window openings. Preformed concretewalls are not often found in residential construction. Another type ofprefabricated walls consists of structural insulated panels (SIP's.)SIP's typically consist of an outer shell formed using sheet metal andan inner core of insulating foam (e.g., expanded polystyrene.) SIP'ssometimes include races (recessed channels) in which electrical wiringcan be positioned after the SIP's are installed. SIP's are sometimesused in residential construction but, as with steel-frame construction,a lack of familiarity in the industry has slowed adoption of thisconstruction method.

SUMMARY OF THE INVENTION

This disclosure is directed to systems and methods for constructionusing modular units, such as wall panels, which have integrated utilityservice, thereby solving one or more of the problems discussed above.One particular embodiment comprises a product including a modularconstruction panel and one or more utility fittings which are integralto the panel. The utility fittings may be for any type of utilityservice, such as electrical, plumbing, HVAC, computer network, phone oraudio/video service. The fittings in the panels may, for example, beelectrical wires or plumbing conduits. The panels may include connectorsfor coupling the utility fittings which are integral to the panel toservice points (such as wiring harnesses or water source pipes) that areexternal to the panel and that provide utility service to the utilityfittings. The panels may also include connectors for coupling theintegral utility fittings to utility fixtures external the panel, suchas light switches, electrical outlets, computer network jacks, phonejacks, faucets, drains, etc. The panels may also include connectors forcoupling the integral utility fittings of one panel to those of anotherpanel. All of these connectors may be quick-connect type connectors.

Another embodiment comprises a building system that includes the panelsdescribed above, as well as a service distribution system and connectorsconfigured to connect the utility fittings within the building panels tothe service distribution system. The service distribution systemreceives utility service from a point external to a building anddelivers utility service to points internal to the building. Thecoupling of the service distribution system to the utility fittingswithin the panels enables the system to provide utility service to theutility fittings, and to utility fixtures which are connected to thefittings.

Numerous other embodiments are also possible.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the invention may become apparent uponreading the following detailed description and upon reference to theaccompanying drawings.

FIG. 1 is a diagram illustrating the interconnection of a centralservice point to multiple modular panels having integrated utilityfittings in accordance with one embodiment.

FIG. 2 is a functional block diagram illustrating the interconnection ofa central service point to multiple modular panels in accordance with analternative embodiment.

FIG. 3 is a diagram illustrating a modular panel having integratedutility fittings in accordance with one embodiment.

FIG. 4 is a diagram illustrating a pair of modular panels havingintegrated utility fittings in accordance with one embodiment.

While the invention is subject to various modifications and alternativeforms, specific embodiments thereof are shown by way of example in thedrawings and the accompanying detailed description. It should beunderstood, however, that the drawings and detailed description are notintended to limit the invention to the particular embodiment which isdescribed. This disclosure is instead intended to cover allmodifications, equivalents and alternatives falling within the scope ofthe present invention as defined by the appended claims.

DETAILED DESCRIPTION

One or more embodiments of the invention are described below. It shouldbe noted that these and any other embodiments described below areexemplary and are intended to be illustrative of the invention ratherthan limiting.

The present disclosure provides details of systems and methods forbuilding construction that make use of environmentally friendly modularpanels which have integrated utilities, such as electrical wiring,plumbing, and the like. Exemplary embodiments include:

-   -   individual modular building panels that incorporate utilities        such as electrical wiring or plumbing;    -   means for connecting the modular building panels to each other        and for coupling the utilities that are integrated into the        panels to other parts of a utility system; and    -   whole-house building systems that make use of the modular        building panels to enable the rapid construction of buildings        that have complete and integrated utility systems, such as        plumbing, electrical service, wiring for computer networks,        telephone systems, audio/video systems, etc.

Referring to FIG. 1, block diagram illustrating the interconnection of acentral service point to multiple modular panels having integratedutility fittings is shown. Modular panels 110-112 may be any of avariety of different types of construction panels. For instance, theymay be external wall panels, internal wall panels, or ceiling panels. Itshould be noted that other types of elements (e.g., columns orfir-downs) may also be needed in the construction of a building, andsuch elements may incorporate the same type of utility fittings as wallpanels, and should, for the purposes of this disclosure, be consideredalternative types of modular panels.

Each modular panel incorporates integrated utility fittings. As used inthis disclosure, “utility fittings” refers to any type of wiring, pipingor other material that is used to provide a service (utility) to thebuilding. Typical utilities may include, but are not limited to,electrical service, plumbing, air-conditioning, heating, computernetworks, telephone service, audio/video, etc.

As depicted in FIG. 1, each of modular panels 110-112 is connected to acentral utility service point 120, or an intermediate service point(130, 131.) In this embodiment, central utility service point 120receives service from outside the building and serves as a distributionpoint for the service to the intermediate service points and modularpanels.

It should be noted that the modular panels may be connected to eachother, in addition to being connected directly to the central utilityservice point. Some of the modular panels may alternatively be coupledto the central utility service point through other modular panels. Stillother connection topologies may also be possible.

Central utility service point 120 may provide both utility service andcontrols to the different modular panels. For example, a centralelectrical utility service point may route electricity to a particularmodular panel that will provide electricity to an HVAC system, and itmay also provide control signals to this panel which will be used tocontrol operation of the HVAC system.

Referring to FIG. 2, a functional block diagram illustrating analternative embodiment is shown. In this embodiment, the utility serviceoriginates within the building, rather than external to the building.For example, the utility service may consist of audio/video (e.g.,television) service within the building. The service may originate atcentral service point 220, or it may originate at one of the modularpanels (e.g., 210,) from which it can be distributed to central servicepoint 220 and/or the other modular panels (211, 212.) Although not shownin this figure, internally originated service may be distributed throughintermediate service points or via other topologies as described abovein connection with externally originated service.

It is contemplated that some of the most useful embodiments of thepresent invention will consist of modular wall panels that haveintegrated electrical wiring. Referring to FIG. 3, an exemplary modularpanel is shown. In this embodiment, modular panel 310 is a prefabricatedwall panel that is configured to be installed within the interior of ahouse. The panel may, for example, be placed within a lower track 320and secured to this track and an upper track 321. The tracks may beplumbed (made vertical) and squared as part of the framing process sothat no adjustment of the wall panel is necessary during itsinstallation.

The wiring integrated into modular panel 310 is illustrated by dashedlines 330 and 331. Line 330 represents live wires that provide 120 volt,60 hertz electrical service to a household electrical outlet 340. Thus,electricity is delivered from an external source to central servicepoint 350, and then from the central service point via a wiring harness360 to the modular panel. Wiring harness 360 has a connector 361 whichis designed to be connected to a corresponding connector 311 which iscoupled to the end of the wiring within modular panel 310. Suitableconnectors are commercially available.

Line 331 represents a set of wires that are connected to a wall switch341. These wires are not always live, but are used to complete acircuit, such as a circuit to provide power to an overhead light. Thewires represented by line 331 are connected to wiring harness 360through connectors 311 and 361. Wiring harness 360 is designed toconnect the wires from light switch 341 to a light in a differentmodular panel, as well as central service point.350 in order to make acircuit that allows switch 341 to control the light. Thus, modular panel310 may include wiring that is used for control purposes, as well assimply providing electrical power.

It should be noted that modular panels such as the one shown in FIG. 3can be constructed to various degrees of completeness. That is,different amounts of finish-out may be needed to complete constructionafter installation of the modular panel. In one embodiment, the modularpanel is constructed with an external surface that is equivalent todrywall, so that is only necessary to paint the panel after it isinstalled. In this embodiment, the modular wall panel incorporatesintegrated wiring 330 and 331, but does not include outlet 340 or switch341. Because the specific fixtures that are desired by particular homeowner may not be known, selection and installation of these figures isleft for a finish-out stage of construction. In an alternativeembodiment, however, these fixtures may be included in that constructionof the modular panel. In the embodiment in which the fixtures are notincluded in the modular panel, the panel may simply provide the terminalend of the wires at the position of the outlet/switch so that thefixtures can be connected conventionally, or the panel may providemodular, quick-connect fittings which allow the fixtures to simply beplugged in instead of requiring tools for installation.

In addition to integrating wiring for electrical service as illustratedin FIG. 3, is contemplated that it will be very useful to integrateplumbing into modular panels. Embodiments which integrate plumbing arevery similar to the embodiment of FIG. 3, except that pipes areintegrated into the panels instead of wiring. It should be noted thatthere are commercially available connectors that allow plumbingconnections to be made as easily as plugging in the electricalconnectors described in connection with FIG. 3. These connectors may beincorporated into the design of the modular panel, both at the point atwhich the panel is connected to the central service (e.g., water supplyor water heater,) and at the point at which fixtures (e.g., faucets) areconnected to the integrated plumbing. Again, the level of finish of themodular panel may vary, with the attachment points for the fixturesbeing provided as stub-outs, or as pipes suitable for use with aplumbing quick-connect fitting.

Referring to FIG. 4, another example of the inventive modular panels isshown. In this embodiment, modular panels 401 and 402 are prefabricatedwall panels that are configured to be installed within the interior of ahouse. The panels are again shown mounted to upper and lower tracks,although this is not characteristic of all embodiments. As shown in FIG.4, panel 401 includes both electrical service (indicated by the dashedlines) and plumbing service (indicated by the dotted lines.) At the topof the panel, connections are provided to couple the plumbing and wiringwithin panel 401 to service points that provide the water and electricalservice.

Wall panel 402 has integral electrical fittings in the form of wiring430 and outlet 435. Rather than being coupled directly to an electricalservice point, the fittings in panel 402 are connected to the electricalservice in panel 401 through coupling 440. Thus, in this example, switch420 can control outlet 435 in a different wall panel. Although coupling440 is depicted here as a cable for clarity, alternative connectors,such as direct male-female connectors can be installed in the panels sothat they are automatically connected when the panels are mounted nextto each other.

It should be noted that, although larger plumbing and ducting may bemore difficult to accommodate than smaller utility fittings, such aswater supply lines and electrical wiring, it is possible to do so. Inone embodiment, the modular panels designed to accommodate smallerfittings may be thinner, while panels incorporating larger fittings(e.g., waste water drain lines) may be thicker, thereby allowing thelines to be integrated into the panels. Also, as noted above, the“panels” may include other architectural elements, such as columns,which can easily accommodate larger fittings (e.g., ducting andlarger-diameter pipes.)

The benefits and advantages which may be provided by the presentinvention have been described above with regard to specific embodiments.These benefits and advantages, and any elements or limitations that maycause them to occur or to become more pronounced are not to be construedas critical, required, or essential features of any or all of theclaims. As used herein, the terms “comprises,” “comprising,” or anyother variations thereof, are intended to be interpreted asnon-exclusively including the elements or limitations which follow thoseterms. Accordingly, a system, method, or other embodiment that comprisesa set of elements is not limited to only those elements, and may includeother elements not expressly listed or inherent to the claimedembodiment.

While the present invention has been described with reference toparticular embodiments, it should be understood that the embodiments areillustrative and that the scope of the invention is not limited to theseembodiments. Many variations, modifications, additions and improvementsto the embodiments described above are possible. It is contemplated thatthese variations, modifications, additions and improvements fall withinthe scope of the invention as detailed within the following claims.

1. A product comprising: a modular construction panel; and one or more utility fittings which are integral to the panel.
 2. The product of claim 1, wherein the utility fittings are selected from the group consisting of: electrical wires; and plumbing conduits.
 3. The product of claim 1, wherein the utility fittings comprise fittings for a utility service selected from the group consisting of: electrical service; plumbing service; HVAC service; network service; phone service; and audio/video service.
 4. The product of claim 1, wherein the utility fittings comprise fittings for two or more different utility services.
 5. The product of claim 1, wherein the panel comprises one or more connectors configured to couple the utility fittings integral to the panel to one or more service points that provide utility service to the utility fittings.
 6. The product of claim 5, wherein the one or more service points comprise intermediate service points, and wherein each of the intermediate service points is configured to be coupled to a corresponding central service point that provides utility service to the intermediate service point.
 7. The product of claim 5, wherein the utility fittings comprise electrical fittings and the service points comprise a wiring harness.
 8. The product of claim 5, wherein the utility fittings comprise plumbing fittings and the service points comprise a plumbing manifold.
 9. The product of claim 6, wherein the connectors comprise quick-connect fittings.
 10. The product of claim 6, wherein the connectors are configured to couple utility fittings which are integral to a first panel to utility fittings which are integral to a second panel.
 11. The product of claim 1, wherein the panel comprises one or more quick-connect connectors configured to couple utility fixtures which are external to the panel to the utility fittings which are integral to the panel.
 12. The product of claim 1, wherein the panel comprises one or more connectors configured to couple utility fittings within the panel to utility fittings within a different panel.
 13. A building system comprising: a service distribution system configured to receive utility service from a point external to a building and to deliver utility service to one or more points internal to the building; a plurality of modular building panels having integral utility fittings; and one or more connectors configured to couple the utility fittings of the building panels to the service distribution system to provide utility service to the utility fittings.
 14. The system of claim 13, wherein the utility fittings comprise electrical wiring embedded within the building panels and the service distribution system comprises a wiring harness.
 15. The system of claim 14, wherein the utility fittings further comprise one or more electrical fixtures.
 16. The system of claim 13, wherein the utility fittings comprise plumbing conduits embedded within the building panels and the service distribution system comprises a water distribution system.
 17. The system of claim 16, wherein the utility fittings further comprise one or more plumbing fixtures.
 18. The system of claim 13, wherein the connectors comprise quick-connect fittings that are configured to be coupled to the modular building panels and to the service distribution system without tools. 